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No Drawing.

To all whom it may concern;

Be it known that we, LAWRENCE V. BE!)- MAN, a citizen of Canada, who has taken his first papers for citizenship in the United States, a resident of Evanston, Cook county, Illinois, ARCHIE WEITH and FRANK P. BROOK, citizens of the United States, residing at Chicago, in the county of Cook and State of Illinois, have invented a new and useful Improvement in Processes of Producin Phenolic Condensation Products, of which the following is a specification.

This'invention relates-particularly to the production of a phenolic condensation product from a phenolic body and formaldehyde; and the improved process is particularly desirable for use in producing a transparent or semi-transparent product.

The present invention provides a simple and easily practised method of producing a phenolic condensation product from a phenolic body and formaldehyde, without the use of a catalyzing agent.

The improved process may be practised as fdllows:

Mix together 3 parts of a 40 per cent. solution of formaldehyde (CI-I 0) and 5 parts of phenol (C H OH); boil the mixture/at'atmospheric pressure for a period which will vary according to the quantity and the precise character of the phenolic body employed, continuing the boiling usually from 60 to 120 hours, until there results a lower layer in the nature of a viscous and an upper layer of water which .is virtually free from formaldehyde, but which may contain from a'trace to perhaps 2 per cent. of formaldehyde.

It is ordinarily desirable to use phenol or a phenolic body'composed largely of phenol and comp-using its homologues, or some of them "(such as ortho, meta and para,

- cresol), where a clear, transparent product is desired. However, cresol or a mixture of cresols may be. used where a cheaper product is desired and where the-question of color isnot of great importance. Ordinary commercial cresolma be used, in which case the boiling period may be. shortened, so as to cover. a period from' four to twelve hours; and if crude cresol be used, the periodmay be shortened 'to about two In using pure-phenol, or' approximately Specification of Letters Patent.

Patented July 15, 1919..

Application filed September 16, 1915. serial No. 254,368.

pure phenol, the reaction may be hurried y closing the still or reflux condenser and allowing the pressure to increase until the temperature rises to 125 0., or higher, or well above 100 *C., in which case the boiling period may be reduced so that it need not exceed twelve to eighteen hours.

The mixture formaldehyde substantially disappears from the supernatant watery layer, and this may be done without unduly hardening the resin or gelatinizing it, so that extreme care is unnecessary in dealing with the material at this stage.

After producing a resinous mass containing a large excess of phenol in the manner described, the mass is poured into an evaporator, fitted with a sti discarded. There is then added 2 parts of formaldehyde, that is, two-thirds of the original amount of formaldehyde employed, and this is stirred into the mass in the evaporating tank, the mass being, at the beginning of this operation, at a temperature of about 100 C; While stirring in the additional formaldehyde, the mass is allowed to cool to about to 7 0 C. The mass is then boiled and rapidly concentrated, the. water evaporating and some of the formaldehyde escaping, which, however, may be condensed and collected. This heating operation may be carried on under atmospheric pressure and the temperature will rise to 115 0. or possibly somewhat higher. Ordinarily, it is desirable to carry the concentration to a point which renders the mass quite viscous but still permits pouring. ,The boiling should be stopped before the material reaches the gelatinous state.

After the concentrating operation, there preferably is introduced into the mass a. small additional amountof formaldehyde, say three to five per cent. of the mass to replace any loss occurring dur1ng concentration, and the material 1s poured -1nto molds and allowed to s'et" 'at a temperature of about 50 C. to 100 C. After the material has become s'ufliciently firm or set, it is removed from the molds and kept at a temperature of, say frond 50 to 100 C.

rrer, the water being may be boiled until the" forf'a period of several weeksfor several months, depending on the thickness of the -mass. The material may remain in the molds for a period of several days to enable it to become sufliciently firmto be removed 'a high-grade phenolic body is employed in the manufacture, .the condensation product is of amber-like color, but may have a tinge The material is,

and substanof orange or red in it. however hard and tenacious, tially transparent,

The material may be given a finer color, reater tenacity and finer temper by subecting it, after the prolonged mild heat treatment, to a higher temperature for a comparatively short period of time. In this manner,there may be produced a material which may be machined, sawed, sandpapered, etc., more satisfactorily. For instance, the material after treating at a higher temperature, may be sandpapered and buffed with much better. effect and at smaller cost, as 'ng of the sandpaper or buffing material will thereby be largely obviated. 7

The preferred method 'of eliminating'the orange or reddish color or tint, which the product may have after the prolonged mild heat treatment, is to continue such miild application of heatuntil the material is practically anhydrous and quite hard and capa-' lble of being used commercially for the man ufacture of pipe-stems, cigar-holders and the like, and then subject the block of material, in a kiln, to a temperature above 100 C. for a period of several days. It is preferred to employ a temperature of approximately 125 C. for this auxiliary heat treatment, although it is practicable to range to a temperature as high as 150 C. or higher, but unnecessary to exceed 150 C. This results 1n the production of a clear amber, or llght lemon color, and produces a material whlch works more easily, tools better, possesses hlgher tensile strength, is finer tempered, and may be sandpapered and buifed with greater facility. It'is probable that some colloidal change takes place in the material during this treatment, which improves the product, giving it a finer color,';a better temper, and increased tensile strength.

The material produced" in the first step of I the process, which contains 'a large excess of q 'phenol, is soluble in the usual'solvents, and, at'a temperature of about 100 0., may be poured or discharged with facility into the ev porator. The material after concentra ing with a second supply of formalde hyde, molding, and hardening by prolong'fd 'mild heat treatment, is practicallyfi'nfusi- 1e and insoluble, but, as stated, itsqualities may be improved by the, subsequent heat treatment at a higher'temlperature. After such subsequent treatment, the material remains, of course, insoluble and inf-usible.

In the second stage of the process, one may add to the'forma-ldehyde very small proportion of hexamethylenet tramin, say, of one per cent. of the amount of the formaldehyde in the solution. This will result in the production of a material which se more quickly.

In the first step of the process, one may use 30 cubic centimeters of a' 40 per cent. formaldehyde solution and 50 cubic centimeters of phenol, and in the second stage of the process, one may add 20 cubic centimeters of a 40 per cent. solution of formaldehyde.

The color may be varied 'by introducing suitable coloring material's during the second step of the process. For instance, one may introduce auramin, to produce a deep amber color; methyl violet, to produce amethyst; acetyl red, to, produce Wine, etc. The coloring material should be added in small quantity, usually not exceeding J; of 1 percent. of the mass. Oils or waxes may be introduced in small quantity, if-desired, during the second step of the process, to produce opaque material. Ground mica or fish scales may be used to produce a shimmering effect.

The improved process is simple, may be practised with facility, and obviates the use of condensing agents, whether acid, salt or base. The process enables a product of highgrade, great purity and finest qualities to be. produced with great permanence of color and with no deleterious substances included, such as might !be formed, for instance, in an effort to neutralize a condensing agent. It is desirable that the formaldehyde and phd nolic body should be used in such proportions as to ultimately provide slightly more of the phenolic body than corresponds with equl-molecular proportions. For example, it is desirable to have the phenol product correspond with .the union of about 6% phenol groups to six methylene groups. We have formed a satisfactory Sproduct, usmg as high as 7% phenol groups to 6 methylene groups.

The concentration maybe performed in va 0u0, if desired; and the hardening operation may be performed at atmospheric pressure, or'at higher pressure',- 'or at reduced pressure, or in vacuo.

The foregoing detailed description has been giv'enfor clearness of understanding only, and no urmecessary limitation should be understood therefrom, but thev appended: claims should iibe construed as broadly as 1. The-"process of producing :a phenolic 'condensation1prodgct, without the use .of a

dregs of l condensing agent, which comprises; bollmg together a solution of formaldehyde and a phenolic bodylftaken largely in excess of the formaldehyde, until the formaldehyde is substantially eliminated from the supernatant aqueous layer which forms and a viscous gummy lower layer is produced;

discarding the aqueous layer; mixing with and concentrating condenslng agent, whichcomprises: boiling aqueous layer gummy lower layer is produced; dmscard-ing -aldehyde taken in together approximately cent. formaldehyde solution and 5 parts of a phenolic body until the formaldehyde is. substantially eliminated from the supernatant aqueous layer which forms and a viscous gummy lower layer is produced; dis carding the aqueous layer; mixing with the gummy mass a 40 per cent. solution of formproportions of about two-thirds of the original amount of formaldehyde employed' and concentrating at a temperature in excess of 100 0.; pouring the mass into molds and setting at a temperature below 100 0.; and removing the material from the molds and subjecting the same to heat treatment for a prolonged period at a temperaturebelow 100 C.

3. The process of producing a phenolic condensation product, without the use of a condensing agent, which comprises: boiling together about 3 parts of a 40 per cent. formaldehyde solution and .5 parts of phenol, until the formaldehyde is substantially eliminated from the-supernatant aqueous layer which forms and a viscous "gummy lower layer is produced; discarding the aqueous layer; mixing with the gummy mass a 40 per cent. formaldehyde solution in an' amount equal to about two-thirds of the amount employed in the first step, and con-' centrating t a temperature exceeding 100 C.; and then forming the mass and hardening it by subjecting to heat treatment for a prolonged period at a temperature below 100 C.

4. The process of producing a phenolic condensation product, without the use of a condensing agent, 'which comprises: boiling together a solution of formaldehyde and a phenolic body taken largely in excess of the formaldehyde, until the formaldehydeis substantially eliminated from the .supernatant which forms and a viscous 3 parts of a 40 per the aqueous layer; mixing with the gummy mass a solution of formaldehyde in lesser proportion than in the first step and a very small proportion of hexamethylenetetramin and concentrating at a temperature above 100 (1.; pouring the mass into molds and setting at a temperature below 100 (3.;

and removing the material from the molds and hardening it by subjecting to prolonged heat treatment at a temperature below 100 C.

5. The process of producing a phenolic condensation product,which comprises: condensing together a formaldehyde solution and a phenolic body in proportions adapted to produce a hard insoluble body; the same to prolonged heat treatment at a temperature below 100 C. until a hard, resistant and substantially anhydrous body is subjecting produced .throughout the mass; and then subjecting such body to heat treatment for a relatively short period at a temperature exceeding 100 C.

6. The process of producing a phenolic condensation product, which comprises: condensing together a formaldehyde solution and a phenolic body under conditions which afford somewhat more than one phenolic group to each methylene group in the final product; subjecting the material to prolonged heat treatment at a temperature below 100 C. until a hard, resistant and substantially anhydrous body is produced throughout the mass; and then subjecting such body to heat treatment for a relatively short period at a temperature exceedlng 100 C.

7. The process of producing a phenolic condensation product, without the use of a catalyzer, which comprises: boiling together a formaldehyde solution and aphenolic body in proportions affording more than 1% phenolic the formaldehyde is substantially eliminated from the supernatant aqueous layer which forms and a viscousgummy lower layer is produced; discarding the aqueous layer; mixing with the gummy mass a solu% tion of formaldehyde in such quantlty that the final product will correspond with at least one phenol group for each methylene group and concentrating the mixture at a higher temperature; hardenlng the mass by heat treatmentfor a period of several weeks at a temperature below 100 C. until the magroups to each methylene group, until subjecting the same to heat treatment for a relatively short period at a temperature exceeding 100 C.

LAWRENCE V. REDMAN. ARCHIE J. WEITH. FRANK P. BROOK. 

